US20060021307A1 - Particulate trap filter element - Google Patents
Particulate trap filter element Download PDFInfo
- Publication number
- US20060021307A1 US20060021307A1 US10/901,351 US90135104A US2006021307A1 US 20060021307 A1 US20060021307 A1 US 20060021307A1 US 90135104 A US90135104 A US 90135104A US 2006021307 A1 US2006021307 A1 US 2006021307A1
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- US
- United States
- Prior art keywords
- base member
- filter
- filter element
- groove
- filter media
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
- B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
- B01D46/523—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material with means for maintaining spacing between the pleats or folds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/10—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/56—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition
- B01D46/58—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in parallel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
- F01N3/027—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
- B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/12—Metallic wire mesh fabric or knitting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/14—Sintered material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2370/00—Selection of materials for exhaust purification
- F01N2370/22—Selection of materials for exhaust purification used in non-catalytic purification apparatus
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S55/00—Gas separation
- Y10S55/05—Methods of making filter
Definitions
- This disclosure relates generally to a filter element and, more particularly, to a filter element for use in a particulate trap.
- Air pollutants may be composed of gaseous compounds and solid particulate matter, which may include unburned carbon particles called soot.
- a particulate trap includes filter elements designed to trap particulate matter.
- Various filter elements may be implemented to trap particulate matter.
- U.S. Pat. No. 5,500,029 (the '029 patent) issued to Zievers et al. on Mar. 19, 1996, describes using a unitary candle filter to remove particulates from an exhaust flow.
- the candle filter may employ continuous filamentary ceramic material wrapped over a porous ceramic support tube and a mounting assembly.
- the mounting assembly is cemented to the tube to form a unitary ceramic member that is connected to a tube sheet.
- the unitary candle filter of the '029 patent may remove particulates from an exhaust flow of an engine
- the unitary candle filter is not configured for close stacking of one filter element on top of another filter element, thereby limiting design flexibility of a particulate trap employing the unitary candle filter.
- vibrational loading may cause the unitary candle filter to wear and/or fail prematurely.
- the disclosed particulate trap filter element is directed to overcoming one or more of the problems set forth above.
- the present disclosure is directed to a filter element.
- the filter element includes a filter media and at least one base member.
- the filter element further includes a ceramic paste connecting the filter media to the at least one base member.
- the present disclosure is directed to a filter element including a filter media having a portion deformed during assembly.
- the filter element also includes at least one base member having at least one groove. The deformed portion is disposed within the at least one groove.
- the present disclosure is directed to a filter element including a filter media, a base member having at least one groove, and a carrier connected to the filter media.
- the carrier has a protrusion configured to engage the at least one groove.
- the present disclosure is directed to a method of assembling a filter element having a filter media and at least one base member.
- the method includes applying ceramic paste to at least one of the filter media and a groove in the at least one base member.
- the method further includes pressing the filter media into the groove and curing the ceramic paste.
- the present disclosure is directed to a method of assembling a filter element having a filter media and at least one base member.
- the method includes pressing a side of the filter media into a groove in the base member to deform a portion of the side within the groove, thereby connecting the filter media to the base member.
- the present disclosure is directed to a method of assembling a filter element.
- the method includes positioning a carrier member into a groove of a base member and retaining the carrier member within the groove with a lip of the base member.
- the method further includes pressing a filter media into the carrier member.
- FIG. 1 is a diagrammatic illustration of a particulate trap according to an exemplary disclosed embodiment
- FIG. 2A is an exploded view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment
- FIG. 2B is an end view diagrammatic illustration of the filter element of FIG. 2A ;
- FIG. 3A is an exploded view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment
- FIG. 3B is an end view diagrammatic illustration of the filter element of FIG. 3A ;
- FIG. 4A is an exploded view diagrammatic illustration of two filter elements according to an exemplary disclosed embodiment
- FIG. 4B is an end view diagrammatic illustration of the filter elements of FIG. 4A ;
- FIG. 5 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment
- FIG. 6 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment
- FIG. 7 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment
- FIG. 8 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment.
- FIG. 9 is a diagrammatic illustration of a filter element according to an exemplary disclosed embodiment.
- FIG. 1 illustrates an exemplary particulate trap 10 .
- Particulate trap 10 may include a housing 12 and a filter assembly 14 disposed within housing 12 and separated from housing 12 via fibrous ceramic mats 24 .
- Housing 12 may have an inlet 16 configured to receive gaseous emissions from a particulate-producing system (not shown), a main chamber 18 , and an outlet 20 .
- Inlet 16 may have a substantially circular cross-section. It is also contemplated that inlet 16 may have a differently shaped cross-section such as square, rectangular, triangular, or any other suitable cross-section. Inlet 16 may protrude from a first end of housing 12 in a length direction of housing 12 .
- Main chamber 18 may be disposed between inlet 16 and outlet 20 , may have a substantially oval-shaped cross-section along a length direction, and may include rounded outer surfaces.
- housing 12 may have a cross-sectional shape other than oval such as, for example, cylindrical, square, rectangular, or another appropriate shape.
- Outlet 20 may have a substantially circular cross-section. It is also contemplated that outlet 20 may have a differently shaped cross-section such as square, rectangular, triangular, or any other suitable cross-section. Outlet 20 may protrude from a second end of housing 12 in the length direction of housing 12 , opposite the first end. It is contemplated that inlet 16 and outlet 20 may alternately protrude from a side of housing 12 , orthogonal to the length direction.
- Filter assembly 14 may include one or more sub-cartridges 22 .
- Each of sub-cartridges 22 may be stacked on top of another sub-cartridge 22 to form a column of sub-cartridges having a stack direction aligned with the column and a transverse direction orthogonal to the column. It is contemplated that multiple columns of sub-cartridges 22 may be included within filter assembly 14 and/or that multiple filter assemblies 14 may be included within particulate trap 10 .
- Gaseous emissions may enter particulate trap 10 via inlet 16 and flow in parallel through sub-cartridges 22 to exit particulate trap 10 via outlet 20 . It is also contemplated that one or more sub-cartridges 22 may be arranged to receive the gaseous emissions in series. The flow through each sub-cartridge 22 may be transverse relative to the stack direction.
- Ceramic fibrous mat 24 may electrically and thermally insulate housing 12 from filter assembly 14 . It is contemplated that a refractory and electrically non-conductive material other than ceramic such as, for example, a high temperature plastic, may be used to electrically and thermally isolate housing 12 from filter assembly 14 .
- FIGS. 2A and 2B illustrate a sub-cartridge 22 including a filter media 26 and a base member 28 connected to either side of filter media 26 by a ceramic paste 32 .
- An electrically non-conductive coating 30 may be disposed between filter media 26 and base member 28 .
- Each pair of adjacent sub-cartridges 22 may share a common base member 28 (referring to FIG. 1 ), or may alternately have dedicated base members 28 .
- Sub-cartridges 22 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Other dimensional relationships are also contemplated.
- Each filter media 26 may have a first end and a second end, with a serpentine shape extending longitudinally from the first end to the second end.
- Each filter media may include electrically conductive mesh elements that have been sintered together under pressure.
- the electrically conductive mesh elements may include an iron based material such as, for example, Fecralloy®. It is contemplated that mesh elements may also be implemented that are formed from an electrically-conductive material other than Fecralloy® such as, for example, a nickel based material such as Inconel® or Hastelloy®, or another material known in the art. It is further contemplated that filter media 26 may alternately include electrically non-conductive mesh elements such as, for example, porous elements formed from a ceramic material or a high-temperature polymer.
- Filter media 26 may have a longitudinal direction from the first end to the second end and a transverse direction, orthogonal to the longitudinal direction. Filter media 26 may be arranged within particulate trap 12 such that the flow of exhaust is in the transverse direction through filter media 26 .
- Base members 28 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Alternate dimensional relationships of base member 28 are also contemplated. Base members 28 may be formed from a rigid material such as, for example, steel, a fibrous composite, a ceramic, a high temperature plastic, or any other suitable material. Each base member 28 may be disposed between adjacent filter media 26 to provide structural support to filter assembly 14 . Base members 28 may be electrically conductive or electrically non-conductive.
- electrically non-conductive coating 30 may be applied to base member 28 to electrically insulate filter media 26 from base member 28 .
- Electrically non-conductive coating 30 may include any electrically non-conductive material including, for example, a ceramic-based material such as alumina or a high-temperature polymer. Electrically non-conductive coating 30 may be applied to base member 28 through any method known in the art such as, for example, by thermal-spraying.
- Ceramic paste 32 may be configured to bond filter media 26 to base member 28 , to thermally insulate filter media 26 from base member 28 , and to fluidly seal a connection between filter media 26 and base member 28 .
- Ceramic paste 32 may be any ceramic based adhesive that provides sufficient bond strength, ductility, thermal insulating, and fluid sealing characteristics such as, for example, a phosphate glass-based adhesive, a mica-based adhesive, or any other adhesive known in the Iart.
- Sub-cartridge 22 may be assembled by first applying ceramic paste 32 to either base member 28 or filter media 26 . Filter media 26 and base member 28 may then be pressed together and ceramic paste 32 cured through a drying process.
- the drying process may include, for example, allowing ceramic paste 32 to dry at a predetermined temperature for a predetermined period of time.
- the drying process may also include elevating and then reducing the temperature of the ceramic paste at predetermined rates, or by any other drying process known in the art.
- FIGS. 3A and 3B illustrate an exemplary embodiment of sub-cartridge 22 similar to FIGS. 2A and 2B .
- sub-cartridge 22 may include base members 34 having two grooves 36 located on opposite sides of each base member 34 and aligned with each other in the length and width direction of each base member 34 .
- Each groove 36 may have a generally square cross-section and a path substantially matching the serpentine shape of filter media 26 .
- Each groove 36 may have a width larger than a width of filter media 26 and may be configured to receive both filter media 26 and ceramic paste 32 .
- Groove 36 may provide additional adhering surface area for ceramic paste 32 , as well as support against lateral motion of filter media 26 relative to base members 34 .
- FIGS. 4A and 4B illustrate an exemplary embodiment of two adjacently-stacked sub-cartridges 22 , wherein each sub-cartridge 22 may include base members 38 each having two grooves 40 located on opposite sides of each base member 38 .
- grooves 40 located on either side of base members 38 may be oriented differently with respect to each other.
- grooves 40 may be out of phase with respect to each other.
- grooves 40 may be oriented between 0 and 180 degrees out of phase from each other.
- a phase shift between grooves 40 located on opposite sides of base members 38 may serve to reduce stress concentrations of base members 38 .
- stress concentrations may be reduced by limiting an amount of continuous minimum thickness of base members 38 .
- Grooves 40 that are in phase create a continuous minimum thickness along an entire length of base members 38 .
- filter media 26 of the two adjacently stacked sub-cartridges 22 may also be oriented between 0 and 180 degrees out of phase with respect to each other to accommodate the phase shift between grooves 40 .
- grooves 40 may be in phase with each other, but offset from each other along the width dimension of base members 38 to reduce stress concentrations within base members 38 .
- grooves 40 on either side of base members 38 may be both out of phase and offset in the width direction relative to each other.
- FIG. 5 illustrates an exemplary embodiment of sub-cartridge 22 , wherein each sub-cartridge 22 may include base members 42 each having two grooves 44 located on opposite sides of each base member 42 .
- Grooves 44 may each include two sidewall portions 46 and a bottom surface 48 , each side wall portion having two recesses 50 separated by a protrusion 52 .
- Recesses 50 and protrusion 52 may increase a bond strength between ceramic paste 32 and base members 42 .
- ceramic paste 32 that has filled recesses 50 must first be sheared prior to separation of ceramic paste 32 from base members 42 .
- increased bond strength is further realized because ceramic paste 32 may adhere to the additional surface area of recesses 50 and protrusions 52 .
- base members 42 may have a greater number of recesses 50 and protrusions 52 .
- FIG. 6 illustrates an exemplary embodiment of sub-cartridge 22 , wherein sub-cartridges 22 each may include base members 54 each having two grooves 56 located on opposite sides of each base member 54 .
- each groove 56 may include a curved bottom surface 58 .
- Curved bottom surface 58 may be configured to reduce stress concentrations within base members 54 . The reduced amount of stress concentrations may be particularly advantageous when base members 54 are formed from a brittle material, such as ceramic.
- FIG. 7 illustrates an exemplary embodiment of sub-cartridge 22 including at least one filter media 60 disposed between base members 38 .
- Each filter media 60 may include serpentine-shaped electrically conductive Fecralloy mesh elements that have been sintered together under pressure.
- filter media 60 may include side portions 64 that are deformed during assembly.
- base members 38 may be connected to filter media 60 by deformably pressing side portions 64 of filter media 60 into grooves 40 of base members 38 .
- pressure may be exerted on sidewall portions 66 of groove 40 .
- the pressure exerted on sidewall portions 66 may be sufficient to retain filter media 60 within grooves 40 without the use of ceramic paste. It is also contemplated that ceramic paste may be used in conjunction with deformably assembled filter media 60 .
- One base member 38 may be shared between adjacent filter media 60 to provide structural support to filter assembly 14 (referring to FIG. 1 ).
- Electrically non-conductive coating 30 may be included within sub-cartridge 22 between side portions 64 and base members 38 when base members 38 are formed from an electrically conductive material.
- FIG. 8 illustrates an exemplary embodiment of sub-cartridge 22 having filter media 60 and base members 68 .
- each base member 68 may include relief features 70 located on either side of each groove 71 .
- Relief features 70 may allow protrusions 73 between relief features 70 and grooves 71 to flex away from groove 71 as filter media 60 is pressed into grooves 71 .
- base members 68 may be formed through a stamping process, with relief features 70 providing a relief of stress built up during the stamping process. Relief features 70 , in this manner, may reduce the risk of structurally damaging base members 68 during assembly of sub-cartridge 22 and ensure a tight hold on filter media 60 .
- FIG. 9 illustrates an exemplary embodiment, wherein each sub-cartridge 22 may include at least one filter media 72 and a base member 74 disposed on each side of filter media 72 .
- Each base member 74 may be connected to filter media 72 via a carrier member 76 .
- Filter media 72 may include serpentine-shaped electrically-conductive Fecralloy mesh elements sintered together under pressure. It is contemplated that mesh elements may also be implemented that are formed from an electrically-conductive material other than Fecralloy. It is further contemplated that filter media 72 may alternately include electrically non-conductive mesh elements such as, for example, porous elements formed from a ceramic material or a high-temperature polymer.
- Base members 74 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Alternate dimensional relationships of base member 74 are also contemplated. Base members 74 may be formed from a rigid material such as, for example, steel, a fibrous composite, a ceramic, a high temperature plastic, or any other suitable material. Base member 74 may be disposed between adjacent filter media 72 to provide structural support to filter assembly 14 (referring to FIG. 1 ). Base members 74 may be electrically conductive or electrically non-conductive. When electrically conductive base members 74 are utilized within particulate trap 10 , electrically non-conductive coating 30 may be applied to base member 74 to electrically insulate filter media 72 from base members 74 .
- Each base member 74 may include two grooves 78 , one located on either side of each base member 74 .
- Grooves 78 may be offset from each other along the width direction of base member 74 , out of phase relative to each other, or may be aligned along the width direction of base member 74 . It is also contemplated that grooves 78 may both be offset and out of phase relative to each other.
- Each groove 78 may have a substantially T-shaped cross-section and a trajectory similar to the serpentine shape of filter media 72 .
- Each groove 78 may be configured to receive carrier member 76 .
- the T-shaped cross-section of each groove 78 may include two side wall portions 80 , a bottom surface 82 , and lips 84 protruding from side walls 80 . Lips 84 may be configured to engage carrier member 76 to retain carrier member 76 within grooves 78 , as well as support carrier member 76 against lateral motion of filter media 72 relative to base member 74 .
- Carrier member 76 may include a deformable electrically-conductive metal. It is also contemplated that carrier member 76 may be formed from an electrically non-conductive flexible material such as, for example a high-temperature rubber. Carrier member 76 may have a substantially T-shaped portion 86 and a receiving portion 88 . T-shaped portion 86 may include protrusions 89 configured to engage lips 84 during assembly. Receiving portion 88 may include a groove 90 , configured to receive filter media 72 . Groove 90 may have a width dimension between opposite side wall portions 92 .
- the width dimension of groove 90 may be less than a thickness of filter media 72 such that during assembly, side wall portions 92 of groove 90 flex away from filter media 72 and provide pressure to sides of filter media 72 when assembled, thereby retaining filter media 72 within groove 90 . Alternate dimensional relationships of groove 90 are also contemplated.
- Sub-cartridge 22 of FIG. 9 may be assembled by positioning end-to-end carrier member 76 and base member 74 , aligning T-shaped portion 86 of carrier member 76 with the T-shape of groove 78 , and threading carrier member 76 into base member 74 .
- Carrier member 76 may alternately be positioned within base member 74 by aligning the serpentine trajectory of carrier member 76 with the serpentine trajectory of groove 78 and pressing carrier member 76 into base member 74 .
- protrusions 89 may flex away from lips 84 as force is applied and return to a substantially unflexed position when T-shaped portion 86 is aligned within the T-shape of groove 78 .
- filter media 72 may be pressed into groove 90 of carrier member 76 .
- the disclosed filter element may be applicable to a particulate trap used for any combustion-type device such as, for example, an engine, a furnace, or any other device known in the art where the removal of particulate matter from an exhaust flow is desired. It is also contemplated that disclosed particulate filter element may be used with a non-combustion type device such as, for example, a dust collection system.
- particulate trap 10 may be compact with little or no wasted space between sub-cartridges 22 .
- particulate trap 10 may be expandable in both a length direction and a transverse direction.
- sub-cartridge 22 is supported on two opposite sides, sub-cartridge 22 is substantially stable and capable of resisting vibrational loading. This resistance to vibrational loading may provide for extended life of particulate trap 10 .
Abstract
Description
- This disclosure relates generally to a filter element and, more particularly, to a filter element for use in a particulate trap.
- Internal combustion engines, including diesel engines, gasoline engines, natural gas engines, and other engines known in the art may exhaust a complex mixture of air pollutants. The air pollutants may be composed of gaseous compounds and solid particulate matter, which may include unburned carbon particles called soot.
- Due to increased attention on the environment, exhaust emission standards have become more stringent, and the amount of particulates emitted from an engine may be regulated depending on the type of engine, size of engine, and/or class of engine. One method that has been implemented by engine manufacturers to comply with the regulation of particulate matter exhausted to the environment has been to remove the particulate matter from the exhaust flow of an engine using a particulate trap. A particulate trap includes filter elements designed to trap particulate matter.
- Various filter elements may be implemented to trap particulate matter. For example, U.S. Pat. No. 5,500,029 (the '029 patent) issued to Zievers et al. on Mar. 19, 1996, describes using a unitary candle filter to remove particulates from an exhaust flow. The candle filter may employ continuous filamentary ceramic material wrapped over a porous ceramic support tube and a mounting assembly. The mounting assembly is cemented to the tube to form a unitary ceramic member that is connected to a tube sheet.
- Although the unitary candle filter of the '029 patent may remove particulates from an exhaust flow of an engine, the unitary candle filter is not configured for close stacking of one filter element on top of another filter element, thereby limiting design flexibility of a particulate trap employing the unitary candle filter. In addition, because the unitary candle filter is mounted on only one end, vibrational loading may cause the unitary candle filter to wear and/or fail prematurely.
- The disclosed particulate trap filter element is directed to overcoming one or more of the problems set forth above.
- In one aspect, the present disclosure is directed to a filter element. The filter element includes a filter media and at least one base member. The filter element further includes a ceramic paste connecting the filter media to the at least one base member.
- In another aspect, the present disclosure is directed to a filter element including a filter media having a portion deformed during assembly. The filter element also includes at least one base member having at least one groove. The deformed portion is disposed within the at least one groove.
- In yet another aspect, the present disclosure is directed to a filter element including a filter media, a base member having at least one groove, and a carrier connected to the filter media. The carrier has a protrusion configured to engage the at least one groove.
- In yet another aspect, the present disclosure is directed to a method of assembling a filter element having a filter media and at least one base member. The method includes applying ceramic paste to at least one of the filter media and a groove in the at least one base member. The method further includes pressing the filter media into the groove and curing the ceramic paste.
- In yet another aspect, the present disclosure is directed to a method of assembling a filter element having a filter media and at least one base member. The method includes pressing a side of the filter media into a groove in the base member to deform a portion of the side within the groove, thereby connecting the filter media to the base member.
- In yet another aspect, the present disclosure is directed to a method of assembling a filter element. The method includes positioning a carrier member into a groove of a base member and retaining the carrier member within the groove with a lip of the base member. The method further includes pressing a filter media into the carrier member.
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FIG. 1 is a diagrammatic illustration of a particulate trap according to an exemplary disclosed embodiment; -
FIG. 2A is an exploded view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; -
FIG. 2B is an end view diagrammatic illustration of the filter element ofFIG. 2A ; -
FIG. 3A is an exploded view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; -
FIG. 3B is an end view diagrammatic illustration of the filter element ofFIG. 3A ; -
FIG. 4A is an exploded view diagrammatic illustration of two filter elements according to an exemplary disclosed embodiment; -
FIG. 4B is an end view diagrammatic illustration of the filter elements ofFIG. 4A ; -
FIG. 5 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; -
FIG. 6 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; -
FIG. 7 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; -
FIG. 8 is an end view diagrammatic illustration of a filter element according to an exemplary disclosed embodiment; and -
FIG. 9 is a diagrammatic illustration of a filter element according to an exemplary disclosed embodiment. -
FIG. 1 illustrates an exemplaryparticulate trap 10.Particulate trap 10 may include ahousing 12 and afilter assembly 14 disposed withinhousing 12 and separated fromhousing 12 via fibrousceramic mats 24. -
Housing 12 may have aninlet 16 configured to receive gaseous emissions from a particulate-producing system (not shown), amain chamber 18, and anoutlet 20.Inlet 16 may have a substantially circular cross-section. It is also contemplated thatinlet 16 may have a differently shaped cross-section such as square, rectangular, triangular, or any other suitable cross-section.Inlet 16 may protrude from a first end ofhousing 12 in a length direction ofhousing 12.Main chamber 18 may be disposed betweeninlet 16 andoutlet 20, may have a substantially oval-shaped cross-section along a length direction, and may include rounded outer surfaces. It is also contemplated thathousing 12 may have a cross-sectional shape other than oval such as, for example, cylindrical, square, rectangular, or another appropriate shape.Outlet 20 may have a substantially circular cross-section. It is also contemplated thatoutlet 20 may have a differently shaped cross-section such as square, rectangular, triangular, or any other suitable cross-section.Outlet 20 may protrude from a second end ofhousing 12 in the length direction ofhousing 12, opposite the first end. It is contemplated thatinlet 16 andoutlet 20 may alternately protrude from a side ofhousing 12, orthogonal to the length direction. -
Filter assembly 14 may include one or more sub-cartridges 22. Each of sub-cartridges 22 may be stacked on top of another sub-cartridge 22 to form a column of sub-cartridges having a stack direction aligned with the column and a transverse direction orthogonal to the column. It is contemplated that multiple columns ofsub-cartridges 22 may be included withinfilter assembly 14 and/or thatmultiple filter assemblies 14 may be included withinparticulate trap 10. Gaseous emissions may enterparticulate trap 10 viainlet 16 and flow in parallel throughsub-cartridges 22 to exitparticulate trap 10 viaoutlet 20. It is also contemplated that one or more sub-cartridges 22 may be arranged to receive the gaseous emissions in series. The flow through each sub-cartridge 22 may be transverse relative to the stack direction. - Ceramic
fibrous mat 24 may electrically and thermally insulatehousing 12 fromfilter assembly 14. It is contemplated that a refractory and electrically non-conductive material other than ceramic such as, for example, a high temperature plastic, may be used to electrically and thermally isolatehousing 12 fromfilter assembly 14. -
FIGS. 2A and 2B illustrate a sub-cartridge 22 including afilter media 26 and abase member 28 connected to either side offilter media 26 by aceramic paste 32. An electricallynon-conductive coating 30 may be disposed betweenfilter media 26 andbase member 28. Each pair ofadjacent sub-cartridges 22 may share a common base member 28 (referring toFIG. 1 ), or may alternately have dedicatedbase members 28. Sub-cartridges 22 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Other dimensional relationships are also contemplated. - Each
filter media 26 may have a first end and a second end, with a serpentine shape extending longitudinally from the first end to the second end. Each filter media may include electrically conductive mesh elements that have been sintered together under pressure. The electrically conductive mesh elements may include an iron based material such as, for example, Fecralloy®. It is contemplated that mesh elements may also be implemented that are formed from an electrically-conductive material other than Fecralloy® such as, for example, a nickel based material such as Inconel® or Hastelloy®, or another material known in the art. It is further contemplated thatfilter media 26 may alternately include electrically non-conductive mesh elements such as, for example, porous elements formed from a ceramic material or a high-temperature polymer.Filter media 26 may have a longitudinal direction from the first end to the second end and a transverse direction, orthogonal to the longitudinal direction.Filter media 26 may be arranged withinparticulate trap 12 such that the flow of exhaust is in the transverse direction throughfilter media 26. -
Base members 28 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Alternate dimensional relationships ofbase member 28 are also contemplated.Base members 28 may be formed from a rigid material such as, for example, steel, a fibrous composite, a ceramic, a high temperature plastic, or any other suitable material. Eachbase member 28 may be disposed betweenadjacent filter media 26 to provide structural support to filterassembly 14.Base members 28 may be electrically conductive or electrically non-conductive. - When electrically
conductive base members 28 are utilized withinparticulate trap 10, electricallynon-conductive coating 30 may be applied tobase member 28 to electrically insulatefilter media 26 frombase member 28. Electricallynon-conductive coating 30 may include any electrically non-conductive material including, for example, a ceramic-based material such as alumina or a high-temperature polymer. Electricallynon-conductive coating 30 may be applied tobase member 28 through any method known in the art such as, for example, by thermal-spraying. -
Ceramic paste 32 may be configured tobond filter media 26 tobase member 28, to thermally insulatefilter media 26 frombase member 28, and to fluidly seal a connection betweenfilter media 26 andbase member 28.Ceramic paste 32 may be any ceramic based adhesive that provides sufficient bond strength, ductility, thermal insulating, and fluid sealing characteristics such as, for example, a phosphate glass-based adhesive, a mica-based adhesive, or any other adhesive known in the Iart. - Sub-cartridge 22 may be assembled by first applying
ceramic paste 32 to eitherbase member 28 orfilter media 26.Filter media 26 andbase member 28 may then be pressed together andceramic paste 32 cured through a drying process. The drying process may include, for example, allowingceramic paste 32 to dry at a predetermined temperature for a predetermined period of time. The drying process may also include elevating and then reducing the temperature of the ceramic paste at predetermined rates, or by any other drying process known in the art. -
FIGS. 3A and 3B illustrate an exemplary embodiment of sub-cartridge 22 similar toFIGS. 2A and 2B . In this embodiment, however, sub-cartridge 22 may includebase members 34 having twogrooves 36 located on opposite sides of eachbase member 34 and aligned with each other in the length and width direction of eachbase member 34. Eachgroove 36 may have a generally square cross-section and a path substantially matching the serpentine shape offilter media 26. Eachgroove 36 may have a width larger than a width offilter media 26 and may be configured to receive bothfilter media 26 andceramic paste 32.Groove 36 may provide additional adhering surface area forceramic paste 32, as well as support against lateral motion offilter media 26 relative tobase members 34. -
FIGS. 4A and 4B illustrate an exemplary embodiment of two adjacently-stacked sub-cartridges 22, wherein each sub-cartridge 22 may includebase members 38 each having twogrooves 40 located on opposite sides of eachbase member 38. However, in contrast to the embodiment ofFIGS. 3A and 3B ,grooves 40 located on either side ofbase members 38, may be oriented differently with respect to each other. In particular,grooves 40 may be out of phase with respect to each other. In one embodiment,grooves 40 may be oriented between 0 and 180 degrees out of phase from each other. A phase shift betweengrooves 40 located on opposite sides ofbase members 38 may serve to reduce stress concentrations ofbase members 38. Specifically, stress concentrations may be reduced by limiting an amount of continuous minimum thickness ofbase members 38.Grooves 40 that are in phase create a continuous minimum thickness along an entire length ofbase members 38. Whengrooves 40 withinfilter assembly 14 are oriented differently between two adjacently stackedsub-cartridges 22,filter media 26 of the two adjacently stacked sub-cartridges 22 may also be oriented between 0 and 180 degrees out of phase with respect to each other to accommodate the phase shift betweengrooves 40. It is contemplated thatgrooves 40 may be in phase with each other, but offset from each other along the width dimension ofbase members 38 to reduce stress concentrations withinbase members 38. It is further contemplated thatgrooves 40 on either side ofbase members 38 may be both out of phase and offset in the width direction relative to each other. -
FIG. 5 illustrates an exemplary embodiment ofsub-cartridge 22, wherein each sub-cartridge 22 may includebase members 42 each having twogrooves 44 located on opposite sides of eachbase member 42.Grooves 44 may each include twosidewall portions 46 and abottom surface 48, each side wall portion having tworecesses 50 separated by aprotrusion 52.Recesses 50 andprotrusion 52 may increase a bond strength betweenceramic paste 32 andbase members 42. In particular,ceramic paste 32 that has filledrecesses 50 must first be sheared prior to separation ofceramic paste 32 frombase members 42. In addition, increased bond strength is further realized becauseceramic paste 32 may adhere to the additional surface area ofrecesses 50 andprotrusions 52. It is contemplated thatbase members 42 may have a greater number ofrecesses 50 andprotrusions 52. -
FIG. 6 illustrates an exemplary embodiment ofsub-cartridge 22, wherein sub-cartridges 22 each may includebase members 54 each having twogrooves 56 located on opposite sides of eachbase member 54. However, in contrast togrooves 36 ofFIGS. 3A and 3B , eachgroove 56 may include acurved bottom surface 58.Curved bottom surface 58 may be configured to reduce stress concentrations withinbase members 54. The reduced amount of stress concentrations may be particularly advantageous whenbase members 54 are formed from a brittle material, such as ceramic. -
FIG. 7 illustrates an exemplary embodiment of sub-cartridge 22 including at least onefilter media 60 disposed betweenbase members 38. Eachfilter media 60 may include serpentine-shaped electrically conductive Fecralloy mesh elements that have been sintered together under pressure. In contrast to filtermedia 26 ofFIGS. 2A-2B ,filter media 60 may includeside portions 64 that are deformed during assembly. In particular,base members 38 may be connected to filtermedia 60 by deformablypressing side portions 64 offilter media 60 intogrooves 40 ofbase members 38. As eachside portion 64 deforms withingroove 40, pressure may be exerted onsidewall portions 66 ofgroove 40. The pressure exerted onsidewall portions 66 may be sufficient to retainfilter media 60 withingrooves 40 without the use of ceramic paste. It is also contemplated that ceramic paste may be used in conjunction with deformably assembledfilter media 60. - One
base member 38 may be shared betweenadjacent filter media 60 to provide structural support to filter assembly 14 (referring toFIG. 1 ). Electricallynon-conductive coating 30 may be included withinsub-cartridge 22 betweenside portions 64 andbase members 38 whenbase members 38 are formed from an electrically conductive material. -
FIG. 8 illustrates an exemplary embodiment of sub-cartridge 22 havingfilter media 60 andbase members 68. However, in contrast tobase members 38 ofFIG. 7 , eachbase member 68 may include relief features 70 located on either side of eachgroove 71. Relief features 70 may allowprotrusions 73 between relief features 70 andgrooves 71 to flex away fromgroove 71 asfilter media 60 is pressed intogrooves 71. If is also contemplated thatbase members 68 may be formed through a stamping process, with relief features 70 providing a relief of stress built up during the stamping process. Relief features 70, in this manner, may reduce the risk of structurallydamaging base members 68 during assembly ofsub-cartridge 22 and ensure a tight hold onfilter media 60. -
FIG. 9 illustrates an exemplary embodiment, wherein each sub-cartridge 22 may include at least onefilter media 72 and abase member 74 disposed on each side offilter media 72. Eachbase member 74 may be connected to filtermedia 72 via acarrier member 76. -
Filter media 72 may include serpentine-shaped electrically-conductive Fecralloy mesh elements sintered together under pressure. It is contemplated that mesh elements may also be implemented that are formed from an electrically-conductive material other than Fecralloy. It is further contemplated thatfilter media 72 may alternately include electrically non-conductive mesh elements such as, for example, porous elements formed from a ceramic material or a high-temperature polymer. -
Base members 74 may be substantially box-shaped, with a length dimension, a width dimension less than the length dimension, and a thickness dimension less than the width dimension. Alternate dimensional relationships ofbase member 74 are also contemplated.Base members 74 may be formed from a rigid material such as, for example, steel, a fibrous composite, a ceramic, a high temperature plastic, or any other suitable material.Base member 74 may be disposed betweenadjacent filter media 72 to provide structural support to filter assembly 14 (referring toFIG. 1 ).Base members 74 may be electrically conductive or electrically non-conductive. When electricallyconductive base members 74 are utilized withinparticulate trap 10, electricallynon-conductive coating 30 may be applied tobase member 74 to electrically insulatefilter media 72 frombase members 74. - Each
base member 74 may include twogrooves 78, one located on either side of eachbase member 74.Grooves 78 may be offset from each other along the width direction ofbase member 74, out of phase relative to each other, or may be aligned along the width direction ofbase member 74. It is also contemplated thatgrooves 78 may both be offset and out of phase relative to each other. Eachgroove 78 may have a substantially T-shaped cross-section and a trajectory similar to the serpentine shape offilter media 72. Eachgroove 78 may be configured to receivecarrier member 76. The T-shaped cross-section of eachgroove 78 may include twoside wall portions 80, abottom surface 82, andlips 84 protruding fromside walls 80.Lips 84 may be configured to engagecarrier member 76 to retaincarrier member 76 withingrooves 78, as well assupport carrier member 76 against lateral motion offilter media 72 relative tobase member 74. -
Carrier member 76 may include a deformable electrically-conductive metal. It is also contemplated thatcarrier member 76 may be formed from an electrically non-conductive flexible material such as, for example a high-temperature rubber.Carrier member 76 may have a substantially T-shapedportion 86 and a receivingportion 88. T-shapedportion 86 may includeprotrusions 89 configured to engagelips 84 during assembly. Receivingportion 88 may include a groove 90, configured to receivefilter media 72. Groove 90 may have a width dimension between oppositeside wall portions 92. The width dimension of groove 90 may be less than a thickness offilter media 72 such that during assembly,side wall portions 92 of groove 90 flex away fromfilter media 72 and provide pressure to sides offilter media 72 when assembled, thereby retainingfilter media 72 within groove 90. Alternate dimensional relationships of groove 90 are also contemplated. -
Sub-cartridge 22 ofFIG. 9 may be assembled by positioning end-to-end carrier member 76 andbase member 74, aligning T-shapedportion 86 ofcarrier member 76 with the T-shape ofgroove 78, and threadingcarrier member 76 intobase member 74.Carrier member 76 may alternately be positioned withinbase member 74 by aligning the serpentine trajectory ofcarrier member 76 with the serpentine trajectory ofgroove 78 and pressingcarrier member 76 intobase member 74. When pressingcarrier member 76 intobase member 74,protrusions 89 may flex away fromlips 84 as force is applied and return to a substantially unflexed position when T-shapedportion 86 is aligned within the T-shape ofgroove 78. Oncecarrier member 76 is positioned withingroove 78 ofbase member 74,filter media 72 may be pressed into groove 90 ofcarrier member 76. - The disclosed filter element may be applicable to a particulate trap used for any combustion-type device such as, for example, an engine, a furnace, or any other device known in the art where the removal of particulate matter from an exhaust flow is desired. It is also contemplated that disclosed particulate filter element may be used with a non-combustion type device such as, for example, a dust collection system.
- Because
sub-cartridges 22 are designed for close stacking of onesub-cartridge 22 on top of another sub-cartridge 22,particulate trap 10 may be compact with little or no wasted space betweensub-cartridges 22. In addition, because sub-cartridges 22 are stackable into afilter assembly 14 andmultiple filter assemblies 14 may be included withinparticulate trap 10,particulate trap 10 may be expandable in both a length direction and a transverse direction. Further, becausesub-cartridge 22 is supported on two opposite sides, sub-cartridge 22 is substantially stable and capable of resisting vibrational loading. This resistance to vibrational loading may provide for extended life ofparticulate trap 10. - It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed filter element without departing from the scope of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the invention being indicated by the following claims and their equivalents.
Claims (38)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/901,351 US7291197B2 (en) | 2004-07-29 | 2004-07-29 | Particulate trap filter element |
DE102005026680A DE102005026680A1 (en) | 2004-07-29 | 2005-06-09 | Particulate trap filter element |
JP2005215674A JP2006035216A (en) | 2004-07-29 | 2005-07-26 | Filtering element for particulate trap |
CNA2005100884747A CN1727647A (en) | 2004-07-29 | 2005-07-28 | Particulate trap filter element |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/901,351 US7291197B2 (en) | 2004-07-29 | 2004-07-29 | Particulate trap filter element |
Publications (2)
Publication Number | Publication Date |
---|---|
US20060021307A1 true US20060021307A1 (en) | 2006-02-02 |
US7291197B2 US7291197B2 (en) | 2007-11-06 |
Family
ID=35730575
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/901,351 Active 2025-08-19 US7291197B2 (en) | 2004-07-29 | 2004-07-29 | Particulate trap filter element |
Country Status (4)
Country | Link |
---|---|
US (1) | US7291197B2 (en) |
JP (1) | JP2006035216A (en) |
CN (1) | CN1727647A (en) |
DE (1) | DE102005026680A1 (en) |
Cited By (2)
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US20050160552A1 (en) * | 2003-06-02 | 2005-07-28 | Takashi Yoshida | Cleaning apparatus |
US20090031855A1 (en) * | 2007-08-03 | 2009-02-05 | Ramberg Charles E | Porous bodies and methods |
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US7785384B2 (en) * | 2007-01-09 | 2010-08-31 | Honeywell International Inc. | Pleated diesel particulate filter assembly |
JP4525748B2 (en) * | 2007-12-20 | 2010-08-18 | 株式会社豊田自動織機 | Exhaust gas treatment equipment |
WO2010008108A1 (en) * | 2008-07-18 | 2010-01-21 | Alantum Corporation | Filter device for reducing automobile exhaust fume |
US8277743B1 (en) | 2009-04-08 | 2012-10-02 | Errcive, Inc. | Substrate fabrication |
US8359829B1 (en) | 2009-06-25 | 2013-01-29 | Ramberg Charles E | Powertrain controls |
US9833932B1 (en) | 2010-06-30 | 2017-12-05 | Charles E. Ramberg | Layered structures |
US9404451B2 (en) * | 2014-04-11 | 2016-08-02 | GM Global Technology Operations LLC | Automotive air cleaner elements with attachment/insulation feature |
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Also Published As
Publication number | Publication date |
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US7291197B2 (en) | 2007-11-06 |
CN1727647A (en) | 2006-02-01 |
DE102005026680A1 (en) | 2006-03-23 |
JP2006035216A (en) | 2006-02-09 |
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